Face mask

ABSTRACT

A mask assembly is provided for delivering gas to a patient that includes a mask body and a breathing circuit interface. The mask body includes an opening for reception of the gas and includes a seal structure for sealingly engaging with the face of the patient and surrounding at least the nose and mouth of the patient. The breathing circuit interface includes a first portion rotatably connected with the mask body and a second portion that is constructed and arranged to releasably connect with a conduit for delivering the gas to the patient through the opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a Continuation under 35 U.S.C. § 120/121 ofU.S. patent application Ser. No. 15/169,024, filed May 31, 2016, whichis a Continuation under 35 U.S.C. § 120/121 of U.S. patent applicationSer. No. 14/048,120, filed Oct. 8, 2013, now U.S. Pat. No. 9,375,544,granted Jun. 28, 2016, which is a Continuation under 35 U.S.C. § 120/121of U.S. patent application Ser. No. 12/742,950, filed May 14, 2010, nowU.S. Pat. No. 8,573,217, granted Nov. 5, 2013, which claims the prioritybenefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No.60/987,843 filed on Nov. 14, 2007, the contents of which are hereinincorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to therapeutic gas delivery systems and,more particularly, to a mask that forms a seal with a patient's faceduring gas delivery.

2. Description of the Related Art

One class of respiratory face mask assemblies can be of two differenttypes: a single limb circuit type and a dual limb circuit type. For asingle limb circuit, the face mask assembly typically includes a valveand an exhaust port, and, for a dual limb circuit, the face maskassembly typically does not include a valve but provides a valvelessconduit instead. Other types of masks may also be useful for differentapplications. Thus, hospitals and other health care facilities typicallystock several different types of face mask assemblies that are used fordifferent applications. Cost and storage space considerations associatedwith stocking several different face mask assemblies can be significant.

SUMMARY OF THE INVENTION

One aspect of the present invention provides a mask assembly forproviding gas to a patient. The mask assembly includes a mask bodyhaving an opening for reception of the gas and a breathing circuitinterface. The mask body includes a seal structure for sealinglyengaging with the face of the patient and surrounding at least the noseand mouth of the patient. The breathing circuit interface includes afirst portion rotatably connected with the mask body and a secondportion that is constructed and arranged to releasably connect with aconduit for delivering the gas to the patient through the opening.

Another aspect of the present invention provides a mask assembly forproviding gas to a patient. The mask assembly includes a mask bodyhaving an opening for reception of the gas and a conduit. The mask bodyincludes a seal structure for sealingly engaging with the face of thepatient and surrounding at least the nose and the mouth of the patient,and a connecting portion. The conduit is releasably connected with theconnecting portion of the mask body. The conduit includes a firstconnector portion which connects with the connecting portion, and asecond connector portion that is constructed and arranged to connectwith tubing, wherein the first connector portion includes a plurality ofrecesses at an interface with the connecting portion to allow exhaledgas to escape therethrough.

In yet another embodiment, the present invention provides a maskassembly kit for providing gas to a patient. The mask assembly kitincludes a mask body having an opening for reception of the gas, afirst, valveless conduit, and a second conduit containing a valve. Themask body includes a seal structure for sealingly engaging with the faceof the patient and surrounding at least the nose and the mouth of thepatient. Each of the conduits includes a first connector portion whichconnects with a connecting portion associated with the mask body, and asecond connector portion constructed and arranged to connect withtubing. The connecting portion of the mask body is constructed andarranged to be selectively attached to the first connector portion ofeither the first conduit or the second conduit.

These and other aspects of the present invention, as well as the methodsof operation and functions of the related elements of structure and thecombination of parts and economies of manufacture, will become moreapparent upon consideration of the following description and theappended claims with reference to the accompanying drawings, all ofwhich form a part of this specification, wherein like reference numeralsdesignate corresponding parts in the various figures. It is to beexpressly understood, however, that the drawings are for the purpose ofillustration and description only and are not intended as a definitionof the limits of the invention. As used in the specification and in theclaims, the singular form of “a”, “an”, and “the” include pluralreferents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of the mask assembly and patient's face inaccordance with an embodiment of the present invention;

FIG. 1B is a left side perspective view of the mask assembly andpatient's face in accordance with an embodiment of the presentinvention;

FIG. 2 is a perspective view of the mask assembly with an entrainmentvalve assembly in accordance with an embodiment of the presentinvention;

FIG. 3 is a perspective exploded view of a mask assembly in accordancewith an embodiment of the present invention;

FIG. 4 is an upper right perspective view of an air entrainment valvewith exhaust ports assembly in accordance with an embodiment of thepresent invention;

FIG. 5 is a left side perspective view of the air entrainment valve withexhaust ports assembly in accordance with an embodiment of the presentinvention;

FIG. 6 is a cross-sectional view of the mask assembly in accordance withan embodiment of the present invention;

FIG. 7 is a cross-sectional view of the entrainment valve assembly inaccordance with an embodiment of the present invention;

FIG. 8 is a perspective view of a valve element in accordance with anembodiment of the present invention;

FIG. 9 is a top perspective view of a valve element in accordance withan embodiment of the present invention;

FIG. 10 is a perspective view of the mask body and the entrainment valveassembly in accordance with an embodiment of the present invention;

FIG. 11 is a perspective view of the mask body and a standard elbowbefore the assembly in accordance with an embodiment of the presentinvention;

FIG. 12 is a perspective view of the mask body and the standard elbowafter the assembly in accordance with an embodiment of the presentinvention;

FIG. 13 is a rear perspective view of the mask assembly in accordancewith an embodiment of the present invention;

FIG. 14 is a front perspective view of a mask headgear attachment postin accordance with an embodiment of the present invention;

FIG. 15 is a rear perspective view of the mask headgear attachment postin accordance with an embodiment of the present invention;

FIG. 16 is a side perspective view of the mask headgear attachment postin accordance with an embodiment of the present invention;

FIG. 17 is a rear perspective view of a mask headgear attachment clip inaccordance with an embodiment of the present invention;

FIG. 18 is a front perspective view of the mask headgear attachment clipin accordance with an embodiment of the present invention;

FIG. 19 is a cross-sectional view taken through the line A-A in FIG. 6and showing the passage of the exhalation grooves through the breathingcircuit interface in accordance with an embodiment of the presentinvention;

FIG. 20 is a front perspective view of an alternative embodiment of themask assembly;

FIG. 21 is an exploded front perspective of the mask assembly inaccordance with an embodiment of the present invention;

FIG. 22 is a front perspective of an alternative mask headgearattachment clip in accordance with an embodiment of the presentinvention; and

FIG. 23 is a rear perspective of an alternative mask headgear attachmentclip in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIGS. 1A, 1B, 2 and 3 show a mask assembly 10 for use in a therapeuticgas delivery in accordance with an embodiment of the present invention.The mask assembly 10 may generally include a mask body 12 having anopening 13 for reception of gas. The mask body 12 includes a sealstructure 20 for sealingly engaging with the face of the patient 27 insurrounding relation to at least the nose and mouth (and optionally theeyes) of the patient 27. The mask assembly 10, in one embodiment, alsoincludes a breathing circuit interface 16 for connecting the mask body12 with a pressurized breathing gas supply. As disclosed in more detaillater, the breathing circuit interface 16 has a first portion 17rotatably connected with the mask body 12 and a second portion 19constructed and arranged to connect with a conduit 18 for delivering thegas to the patient 27 through the opening 13.

In an embodiment, the breathing circuit interface 16 and the conduit 18connects the mask body 12, via a circuit tubing (not shown), to a sourceof gas (not shown), e.g., a blower, a CPAP machine, a ventilator orother suitable device, for providing breathing gas to the patient 27. Aswill be appreciated from further discussions herein, the second portion19 of the breathing circuit interface 16 is releasably connected withthe conduit 18 to enable different types of conduits 18 to be connectedto the mask body 12. In addition, a rotatable or swivel connectionbetween the breathing circuit interface 16 at the first portion 17thereof with the mask body 12 allows the elbow shaped conduit 18 torotate after connection to enable the conduit 18 to extend in anydirection within a 360° of rotation for connecting with the tubing. Itshould be appreciated that for some purposes the breathing circuitinterface 16 may also be considered to be part of the mask body 12.

As shown in FIG. 3, the breathing circuit interface 16 has an annularconfiguration with a generally cylindrical inner surface 23 disposedabout a central opening 29 therethrough. As will be appreciated frommore detailed discussions later, the cylindrical inner surface 23 of thebreathing circuit interface 16 is shaped and configured to provide areleasable friction fit with a generally cylindrical mating surface 25of an appropriate conduit 18 that connects with tubing for receiving abreathable gas.

A plurality of radially outwardly extending ribs 31, which have anincreasing thickness or radial dimension as they extend from the secondportion 19 to the first portion 17 of the breathing circuit interface16, are spaced at regular circumferential intervals. The ribs 31 areintegrally formed as part of the outer surface of the breathing circuitinterface 16. The plurality of ribs 31 located on the outer surface ofthe second portion 19 of the breathing circuit interface 16 provides theuser 27 (or healthcare personnel) a grip to hold the breathing circuitinterface 16 when connecting and disconnecting the conduit 18 to thebreathing circuit interface 16. The ribs 31 also facilitate manualrotation of the breathing circuit interface 16.

In one embodiment, the mask body 12 includes a rigid portion 21, formedfrom a clear plastic material, and the aforementioned flexibleperipheral seal structure 20. The flexible peripheral seal structure 20is attached around the rigid portion 21 of the mask body 12. Aprotrusion 60 extends forwardly from a forward central portion of therigid portion 21 of the mask body 12 and is shaped to accommodate thenose and the mouth of the patient 27. The protrusion 60 is generallypear shape about its periphery 62, where it meets the flatter parts 64of the rigid portion 21 and includes the opening 13 located in theforwardmost portion thereof. The protrusion 60 includes a pair ofindentations 68 located horizontally on either side of the opening 13.The pair of indentations 68 serves as finger receiving indentations andprovides a region for an individual to grip the mask body 12 whenplacing and removing the mask body 12 on the patient's face.

In one embodiment, the mask body 12 is adapted to be connected withheadgear assembly 11 that can be used to mount the mask body 12 on thehead of the patient 27. In an embodiment, a pair of headgear attachmentclips 14 provided for interface and connection with lower headgearmounting strap portions 40 of the headgear assembly 11. A pair ofheadgear attachment members 22 is provided for connectably receiving theheadgear attachment clips 14, and a pair of spaced upper headgear strapretaining tabs 24, each having an elongated opening 50 therethrough, isprovided for receiving upper headgear mounting strap portions 40 of theheadgear assembly 11. The pair of headgear retaining tabs 24 is disposedon the opposite upper sides of the rigid portion 21 of the mask body 12.The pair of headgear attachment members 22 is disposed on opposite,lower sides of the rigid portion 21 of the mask body 12. Each headgearretaining tab 24 is integrally formed with rigid portion 21 and extendsoutwardly from the flexible peripheral seal structure 20, as best seenin FIGS. 2 and 3.

FIG. 4 shows a conduit 18 in accordance with one embodiment. In thisembodiment, the conduit 18 is an entrainment valve assembly 200. Theentrainment valve assembly 200 comprises a generally an elbow shapedtubular member 201 formed from a rigid plastic material, such aspolycarbonate or other plastic material as would be appreciated by oneskilled in the art. In one embodiment, the tubular member 201 is formedfrom a clear, colorless, plastic material. Tubular member 201 includes aprimary inlet 202, a secondary inlet 204 and an outlet 206.

Tubular member 201 includes a first connector portion 230 and a secondconnector portion 232. The first connector portion 230 and the secondconnector portion 232 are generally cylindrical in shape and aregenerally disposed perpendicular to each other. The first connectorportion 230 and second connector portion 232 is joined by a bent tubularregion 233. The first connector portion 230 has aforementioned generallycylindrical outer surface 25 for connection with the breathing circuitinterface 16, while the second connector portion 232 also has acylindrical outer surface 205 for frictionally mating with the innersurfaces of tubing.

The second connector portion 232 is connected to the breathing circuittubing (not shown) and receives pressurized gas from a source ofpressurized gas (e.g., air from a CPAP machine, a blower, a ventilatoror other ventilation device).

The secondary inlet 204 of the entrainment valve assembly 200 comprisesan opening 254 located towards the bent tubular region 233. The opening254 is divided into two equal, generally semi-cylindrical segments by aplanar wall 256. The planar wall 256 of the entrainment valve assembly200 extends through the cylindrical opening 254. The opening 254 allowsthe user 27 to breath in from and out to atmosphere in the absence ofpressurized gas flow being provided into inlet 202. The entrainmentvalve assembly 200, at cylindrical surface 25, further includes aplurality of exhalation grooves 258. The grooves 258 are located at aninterface where the entrainment valve assembly 200 connects with thebreathing circuit interface 16 as will be more fully appreciated fromFIG. 19. The plurality of the exhalation grooves 258 arecircumferentially spaced on surface 25 and placed symmetrically oneither side of the first connector portion 230. Other embodiments arecontemplated in which the exhalation grooves 258 are located anywhere onthe outer surface of the first connector portion 230, where itinterfaces with breathing circuit interface 16.

As clearly shown in FIG. 3, the four exhalation grooves 258 on each sideof the entrainment valve tubular member 201 are placed at an angle withrespect to the horizontal axis on the surface 25 of the entrainmentvalve 200. Specifically, when the tubular member 201 is connected to therigid portion 21 such that the second connector portion 232 of thetubular member 201 points downwards, the four exhalation grooves 258 onone side of the tubular member 201 point upwards at an angle whereas thefour exhalation grooves 258 on the other side of the tubular member 201point downwards at an angle. The angular positioning of the grooves 258allows the exhaled gas to exit the mask in a swirling motion. Inaddition, the angled groove 258 aid in providing a releasable frictionfit between the cylindrical mating surface 25 of the entrainment valveassembly 200 and the cylindrical inner surface 23 of the breathingcircuit interface 16.

The exhalation grooves 258 are sufficiently long so that, when theentrainment valve assembly 200 is pushed as far as it can go into thebreathing circuit interface 16, the grooves 258 still extend outwardlyfrom the breathing circuit interface 16 and provide a path for allowingthe exhaled gas to exit through the grooves 258. In addition, for anyextent of friction fitting engagement between the surfaces 23, 25, thecross-sectional area of the gap or space provided by the grooves 258will be constant, so that the expired gas flow path to the exterior ofthe mask 258 provides constant resistance, irrespective of whether theentrainment valve assembly 200 is fully inserted or somewhat less thanfully inserted into the breathing circuit interface 16.

Referring to FIG. 5, the entrainment valve assembly 200 includes apressure port 260. The pressure port 260 extends from the bent tubularregion 233 of the entrainment valve assembly 200 and is generallyparallel to the second connector portion 232 of the entrainment valveassembly 200. A removable cap 262 is used to close the pressure port260. The cap 262 includes gripping tab 264 to aid in removal of the cap262 from the pressure port 260. A sampling tube (not shown) may bedisposed in fluid communication with the gas within tubular body 201through the pressure port 260. A transducer (not shown) can be securedto the sampling tube, and a processor communicates with the transducer.The processor calculates at least one respiratory parameter using thesignal from the transducer. This is generally used to measure pressureby the ventilator as control feedback to the ventilator.

As shown in FIGS. 6 and 7, the breathing circuit interface 16 includesthe aforementioned first portion 17 and second portion 19. The firstportion 17 is generally circular in shape and includes an annular flatwall 408 that engages a radially inwardly extending flange portion 70 inslidable surface relationship. The flange portion 70 surrounds opening13 in the rigid portion 21 of the mask body 12 (see FIG. 3). The firstportion 17 of the breathing circuit interface 16 further includesgenerally cylindrical protruding portion 409 that extends outwardly froma radially innermost portion of annular surface 408. The cylindricalprotruding portion 409 extends into the opening 13 in the rigid portion21 of the mask body 12. The cylindrical protruding portion 409 has agroove 410 located in the outer cylindrical surface thereof (see FIG.7). The groove 410 accommodates a connecting washer or a bearing 412.The washer 412 in one embodiment is a split ring washer structure thathas an outer periphery thereof that bears against the inner surface ofthe flange 70, and its inner periphery received groove 410 so as torotatably connect the breathing circuit interface 16 with the mask body12. Thus, the breathing circuit interface 16 is rotatably connected withthe rigid portion 21 of the mask body 12. Slight friction at therotatable interface may, in one embodiment, provide at least resistanceto rotation, so that the rotational position of the breathing circuitinterface 16 can be manually set as desired, and it will retain thatposition so that the leg or the second connector portion 232 of theconduit 18 that connects with tubing can be positioned in a desireddirection that is generally retained unless intentionally altered. Inanother embodiment, the friction at the point of rotation can beminimal, to allow free rotation of the breathing circuit interface 16.

In another embodiment, the connection between the breathing circuitinterface 16 and the rigid portion 21 of the mask body 12 may beachieved by using a ball bearing arrangement or any other type bearingarrangement that allows a rotating motion of the breathing circuitinterface 16 with respect to the mask body 12.

As discussed above, the inner surface 23 of the breathing circuitinterface 16 is shaped and configured to engage detachably with an outersurface 25 of the entrainment valve assembly 200 by a friction-fit. Inaddition to allowing friction fit with the entrainment valve assembly200, the inner surface 23 of the breathing circuit interface 16 allowsthe entrainment valve assembly 200 to be removed and interchangeablyfriction fitted with different, other types of the conduits 18 through asimilar friction fit, as will be described in more detail later. Thediameter of the first connector portion 230 is larger than the diameterof the second connector portion 232 of the entrainment valve assembly200 to prevent the wrong end of the valve assembly 200 from beingconnected with interface 16.

The entrainment valve assembly 200 includes a valve member 208. Thevalve member 208 is connected to the tubular member 201 at connectionregion 248 thereof by means of a recess 250 and a barb 526 and a stopmember 528 provided in the valve member 208 (see FIGS. 8 and 9). A rib252 (see FIG. 7), located on the lower portion of the bent tubularregion 233 of the entrainment valve assembly 200, has an outer surfacethereof that is received in recess 250 so as to clamp the connectingregion 248 against a portion 234 of an annular flange 253.

The valve member 208 has a sealing portion 520, having a relativelythin, flat, oval configuration. The sealing portion 520 is made of aflexible material and thus capable of bending upwardly (as shown in thedashed lines in FIG. 7) in response to pressurized gas being forced intothe primary inlet 202. The upward bending continues until an uppersurface 522 of the sealing portion 520 engages an annular lip 235 at theend of a cylindrical wall 254 protruding into the tubular body 201 anddefining the secondary inlet 204. The direction of travel of the sealingportion 520 from its rest position to the upper bent portion is shown byarrow A in FIG. 7. In this upper bent portion, the sealing engagement ofthe upper surface 522 of the valve member 208 with annular lip 235causes the secondary inlet 204 to be sealed so that pressurized gasprovided into the primary inlet 202 does not escape through thesecondary inlet 204.

It should be noted that where gas is not being provided to the patientthrough the primary inlet 202 (e.g., the blower connected with theprimary inlet 202 is not operating), the secondary inlet 204 may serveas both an inlet passage of atmospheric air provided to the patientduring inhalation and an outlet passage for exhalation. In thisinstance, the sealing portion 520 may remain at its at rest position,wherein it forms a seal with an upper surface 259 of the annular flange253, as shown in FIG. 7.

The valve member 208 can be made from rubber, latex, silicone, or anyother elastomeric material as would be appreciated by one skilled in theart.

As can be appreciated most readily from FIG. 4 and FIG. 19 (which is across-sectional view taken through A-A in FIG. 6), the exhalationgrooves 258 form a passage between the exterior surface 25 of thetubular portion 201 and the interior cylindrical surface 23 of thebreathing circuit interface 16. In one embodiment, the exhalationgrooves 258 are provided on opposite lateral sides of the exteriorsurface 25 of the tubular portion 201. In another embodiment, theexhalation grooves may be provided on the inner surface 23 of thebreathing circuit interface 16 rather than on body 201. In addition, asshown as dashed lines in FIG. 7, in another embodiment they mayalternatively, or also, be located at the top portion of the exteriorsurface 25 of the body 201. When the user inhales, a very small fractionof gas may be drawn from atmosphere through the exhalation grooves 258.However, by and large, the pressurized gas forced into the primary inlet202 will create higher pressure within the body 201 than the atmosphericpressure, so that air is mostly forced outwardly through the exhalationpassages 258 (rather than inwardly), even during inhalation. Moreover,as the user exhales, the exhaled gas impacts the centrally incomingairflow through the body 201 and is thus forced to mushroom radiallyoutwardly resulting in a circular flow pattern that effectively flushesthe exhaled gas, and is thus generally directed toward and through theperipheral exhalation grooves 258 to atmosphere.

As best seen in FIG. 6, the flexible peripheral seal portion 20 may havea generally rectangular channel shaped cross-sectional configurationwith three sides 504, 506 and 508. The flexible peripheral sealstructure 20 may be attached to the mask body 12 at side 504. An edge500 of the rigid portion 21 of the mask body 12 engages with an opening502 located in the side 504 of the flexible peripheral seal structure20, such that a layered connection is formed. The parts are then adheredin place, through an adhesive connection, an ultrasonic weld connection,a riveted or a pinned connection or any other type of connection aswould be appreciated by one skilled in the art. Other embodiments arecontemplated in which there is no overlap, such as by attaching therigid portion 21 and flexible peripheral seal structure 20 with theiredges end to end (e.g., by an adhesive connection). The side 506 islocated between side 504 and side 508, providing a gap between sides 504and 508. This gap may provide flexibility to the flexible peripheralseal portion 20, as it conforms to the face of the user 27. The cornersof the flexible peripheral seal portion 20 may be generally rounded. Thelength of the sides 508 and 506 may vary along the periphery of the sealstructure 20 so as to provide a conforming sealing engagement of themask body 12 with the face of the patient 27.

FIGS. 10-12 show the replaceable and interchangeable concept of theconduit 18 with respect to the breathing circuit interface 16.Specifically, in FIGS. 10-12, the entrainment valve assembly 200 isshown being replaced by a standard elbow 300, both of which can be usedas examples for the conduit 18. However, as discussed later, other elbowconfigurations may also be friction fitted with the breathing circuitinterface 16.

FIG. 10 shows the entrainment valve assembly 200 having been removedfrom the mask assembly 10. This can be done by simply pulling theentrainment valve assembly 200 away from the mask assembly 10 to releasefriction fit as discussed earlier. FIGS. 11 and 12 show the maskassembly 10 being connected with the standard elbow 300 by a similarfriction fit. The standard elbow 300 has no internal valve and noexterior exhalation grooves. The standard elbow 300 provides a tubular,elbow shaped body 301 that is otherwise similar to tubular body 201 forproviding a connection between the breathing circuit interface 16 andthe tubing that will provide breathing gas to the mask assembly 10. Thestandard elbow 300 may optionally be provided with the pressure port 260and pressure cap 262 as discussed with respect to the entrainment valveassembly 200. In one embodiment, body 301 is formed from a clear(transparent), but colored (e.g., blue) plastic material.

The removable and replaceable conduits 18 enable the mask assembly 10 tobe functional for different uses, simply by employing the conduit 18 ofchoice.

Though FIGS. 10-12 show the mask assembly 10 that is adapted toaccommodate the entrainment valve assembly 200 and standard elbow 300interchangeably, listed below are some non-limiting examples of othertypes of conduits 18 that can be used interchangeably with the maskassembly 10 described above:

-   -   Conduit with a bronchoscope port to permit the care giver to        perform a bronchoscopy procedure with mask on    -   Conduit with aerosol generator adapter to deliver medication        during NIV    -   Conduit with MDI port to deliver medication using a “Metered        Dose Inhaler”    -   Conduit with port to accommodate a CPAP relief valve    -   Conduit with C02 sensor capabilities to monitor patient    -   Conduit with Volumetric C02 sensor capabilities to monitor        patient VC02    -   Conduit that entrains Heliox or other specialty gases    -   Conduit that adds moisture to inhaled gas    -   Conduit that includes an HME [Heat moisture exchanger]    -   Conduit that incorporates “nano” sensors for a variety of        clinical monitoring capabilities    -   Conduit with Filtered Exhalation [useful in pandemic situations        like SARS]    -   Conduit that enhances the patients ability to “Speak with Mask        On”    -   Conduit that accommodates a NG feeding tube    -   Conduit that reduces/control C02 re-breathing    -   Conduit that aids in secretion clearance    -   Conduit with Standard Elbow    -   Conduit that can be used on a wide range of mask types [Such as        Full, Nasal or Total or Helmet]

It should be appreciated, that the above listed conduit configurationsprovide non-limiting examples of different types, configurations and/orconstructions of conduits that can be provided. It should be appreciatedthat, while these conduits may all be provided with an elbow shapedtubular body; other tubular shapes (such as a straight tubularconfiguration) may alternatively be provided.

Other embodiments are contemplated in which the connection between theconduit 18 and the breathing circuit interface 16 is not a friction fit,but may be achieved by virtue of other types of connections such as aquarter-turn type connection, a snap fit, or any other locking mechanismthat provides a detachable connection between the conduit 18 and thebreathing circuit interface 16.

In yet another embodiment, the first connector portion 230 of theconduit 18 may itself be provided with a swivel coupling, similar to thebreathing circuit interface 16, rather than such structure beingprovided as part of the mask. In that case, the swivel coupling of theelbow can be connected directly to a non-swiveled portion (e.g., anoutwardly projecting cylindrical configuration) surrounding the opening13 in the rigid portion 21 of the mask body 12.

In yet another embodiment, no swivel coupling is provided. Rather, adirect connection between the tubular body (e.g., 201 or 301) isprovided with a correspondingly shaped portion of the rigid portion 21of the mask. In this embodiment, some rotation of the conduits 18 maynevertheless be accommodated via direct sliding friction at the frictionfit connection between rigid portion 21 and the tubular body. However,it is further contemplated that other, non-rotational connections mayalso be provided and will still enable the modularity of designcontemplated herein.

In one aspect of the invention, a mask assembly kit is provided. The kitassembly includes the mask body 12, with or without the rotatableinterface 16, and at least two conduits 18 of different types to enablethe mask body 12 to provide different functionality simply by changingconduit types. For example, the standard elbow 300 (valveless) can beprovided as one conduit, and the entrainment valve assembly 200 can beprovided as another conduit. More than two conduits may be provided, andmore than one mask may be provided, although each of the masks will havea common configuration, while the conduits will have at least twodifferent configurations that fit the mask body.

FIG. 13 shows a rear perspective view of the mask assembly 10. Theflexible seal structure 20 can be clearly seen here. Also shown are theheadgear strap retaining tabs 24 and portions of headgear attachmentmembers 22, which are partially obstructed by the headgear attachmentclips 14. FIGS. 14-16 show the headgear attachment members 22 moreclearly. The headgear attachment members 22 are integrally formed withthe rigid portion 21 and extend outwardly therefrom, beyond the flexibleperipheral seal structure 20. Specifically, the headgear attachmentmembers 22 each have a generally flat web portion 78 integrallyconnected with the rigid portion 21 of the mask body 12, and aconnecting post or barrel 82 disposed at the outer end of the webportion 78. The web portion 78 gradually tapers from the mask body 12 tothe barrel 82. The headgear attachment members 22 each include a frontsurface 84 and a rear surface 86. A reinforcement rib 88, which extendsalong the web 78 from the mask body 12 to the barrel 82, is provided onthe rear surface 86 on each of the webs 78. Each barrel or post 82includes a front face 90 and a rear face 92. The front face 90 of thebarrel 82 is generally semi-cylindrical in shape with a groove 94located centrally thereof, as best seen in FIG. 14. The front face 90has an upper semi-cylindrical surface portion 91 and a lowersemi-cylindrical surface portion 93 on opposite sides of groove 94. Therear face 92 of the barrel 82 includes a channel 96 located betweenopposite ends 104 and 106 of the barrel 82. The channel 96 is dividedinto four segments by three generally semi-circular projections 108, 110and 112 (top projection 108, middle projection 110, and bottomprojection 112). The thickness of the central circular projection 110 isgreater than the thickness of the circular projections 108 and 112.

FIGS. 17 and 18 show one of the headgear attachment clips 14. Theheadgear attachment clips 14 each include a front face 116, a rear face118, a top face 120, a bottom face 122, a first side face 124 and asecond side face 126. When the headgear attachment clip 14 is assembledwith the mask body 12, the top face 120 faces upwards towards theheadgear strap retaining tabs 24 of the mask body 12, the bottom face122 faces away from the headgear strap retaining tabs 24 of the maskbody 12, the first side face 124 faces the mask body 12, and the secondside face 126 faces away from the mask body 12. Finger indentations 128having gripping ribs 129 are located on the top face 120 and the bottomface 122 of the headgear attachment clips 14. The gripping ribs 129provide a region for the patient 27 or care giver to grip the headgearattachment clips 14 while securing or removing the headgear assembly 11with the mask body 12. The headgear attachment clips 14 include anelongated opening 130 that receives the straps 40 of the headgearassembly 11.

As shown in FIG. 17, the rear face 118 of the headgear attachment clips14 includes a cavity 134, which is generally rectangular in shape andincludes three cam fingers 136, 138 and 140 that extend from a wall 133defining one side of the elongated opening 130. The cam fingers 136, 138and 140 extend about half way through the cavity 134. The thickness ofthe central cam finger 138 is greater than the thickness of the upperand lower cam fingers 136 and 140 respectively. The cam fingers 136, 138and 140 are generally rectangular in shape and connected along one sideto wall 133 and on the bottom to a bottom wall 137 of the cavity 134.Each of the cam fingers 136, 138 and 140 has a chamfered edge located onthe top corners 139 that are located away from the side wall 133. Theedges 145 of the cam fingers 136 and 140 that extend downwardly from thecorners 139 are sloped at a positive angle so that they extend away fromwall 133 as they extend downwardly to join bottom wall 137. In contrast,the chamfered corner 139 on the central cam finger 138 terminates at ahard corner 141 that protrudes slightly beyond the edges 145 of camfingers 136 and 140, and then extends at a negative angle to form anundercut, such that its forward edge 149 extends slightly in a directiontowards wall 133 as it extends towards bottom wall 137. The hard corner141 provides a primary point of camming contact with the barrel 82 (andin particular, central projection 110 thereof) to lock and unlock (orconnect and disconnect) the barrel 82 to the headgear attachment clip 14as will be described. The cavity 134 includes an elongated channel 135that does not contain the cam fingers 136, 138 and 140. An outer wall148 of the headgear attachment clip 14 defines one end of the cavity134, opposite the wall 133. The top portion of wall 148 includes achamfered top portion 151, and also includes a pair of overhangs 143.The overhangs 143 serve a similar function to the hard corner 141, butengage with semi-cylindrical surfaces 91 and 93 respectively (see FIG.14), as will be described.

As shown in FIG. 18, the front face 116 of the headgear attachment clips14 includes three rectangular openings 142, 144 and 146 that are locatedin the wall 137. The three rectangular openings 142, 144 and 146 extendinto the channel 135 of the cavity 134 on the rear face 118 (see FIG.17). The openings 142 and 146 are disposed closely to outer wall 148,while the opening 144 is offset and disposed at the bottom of slopingsurface 149 of cam finger 138.

The headgear attachment clips 14 along with the headgear straps 40 areconnected to their respective headgear attachment members 22 by movingthe headgear attachment clips 14 toward the barrels 82 so that thechannel 135 of the headgear attachment clips 14 are forced onto thebarrels 82 of the headgear attachment members 22. Specifically, the camfinger 138 (and specifically, the hard corner 141) of the headgearattachment clips 14 engages with the corresponding semi-circularprojection 110 of the barrel 82, and the overhangs 143 of the headgearattachment clips 14 engage with the surfaces 91 and 93 on the oppositeside of the barrel 82. A camming motion between the cam finger 138 ofthe headgear attachment clips 14 and the corresponding circularprojection 110 of the barrel 82 of the headgear attachment members 22causes a bending of the web portions 78, and a slight flexing of the camfinger 138 and/or circular projection 110 to allow the circularprojection 110 to move past the hard corner 141 and into the channel135. Similarly, the flexing movement of web 78, together with slightflexing of the overhangs 143 and/or surfaces 91 and 93 enable thesurfaces to be cammed passed the overhangs 143. When the barrel 82 isdisposed within channel 135, the overhangs 143 and the hard corner 141prevents the barrel 82 from escaping the channel 135. The overhangs 143of the headgear attachment clips 14 engage with the surfaces 91 and 93on the opposite side of the barrel 82, thus allowing for rotation of theheadgear attachment clip 14 during adjustment or to accommodatedifferent head sizes.

In one embodiment, rather than a camming action the headgear attachmentclips 14 are pulled off or pushed onto the headgear attachment members22 by a snapping action over hard corners 141 without camming, and thecam finger 138 of the headgear attachment clips 14 engages with thecorresponding semi-circular projection 110 of the barrel 82.

To remove headgear attachment clips 14, the user 27 or caregiver placeshis fingers on the finger indentations 128 and pulls the headgearattachment clips 14 in a direction away from the flexible peripheralseal structure 20 towards the protrusion 60. The headgear attachmentclips 14 rotate about an axis defined by the barrel 82 until thechamfered top portions 151 of the wall 148 engages the front surface 84of the web 78. Rotational force applied to the headgear attachment clips14 (e.g., manual force) in a direction forcing surface 151 againstsurface 84 causes a camming action that creates a flexing of theaforementioned parts and surfaces that lock barrel 82 within channel135, so as to cam the barrel 82 out of locking engagement within thechannel 135. In one embodiment, the headgear attachment clips 14 may bemolded from a plastic material, but other materials such as rubber,elastomeric material, or metal are also contemplated.

In another embodiment of the headgear attachment clips 14 as shown inFIGS. 20-23, the headgear attachment clips 14 each include a front face116, a rear face 118, a top face 120, a bottom face 122, a first sideface 124 and a second side face 126. When the headgear attachment clip14 is assembled with the mask body 12, the top face 120 faces upwardstowards the headgear strap retaining tabs 24 of the mask body 12, thebottom face 122 faces away from the headgear strap retaining tabs 24 ofthe mask body 12, the first side face 124 faces the mask body 12, andthe second side face 126 faces away from the mask body 12. The headgearattachment clips 14 include an elongated opening 130 that receives thestraps 40 of the headgear assembly 11. In addition, this embodimentincludes an auxiliary elongated opening 152. The elongated opening 152is defined by an inner auxiliary wall 154, an outer auxiliary wall 156,and side auxiliary walls 158. The inner auxiliary wall extends frombottom face 122.

As shown in FIG. 23, the rear face 118 of the headgear attachment clips14 includes a cavity 134, which is generally rectangular in shape andincludes three cam fingers 136, 138 and 140 that extend from a wall 133defining one side of the elongated opening 130. The cam fingers 136, 138and 140 extend about half way through the cavity 134. The thickness ofthe central cam finger 138 is greater than the thickness of the upperand lower cam fingers 136 and 140 respectively. The cam fingers 136, 138and 140 are generally rectangular in shape and connected along one sideto wall 133 and on the bottom to a bottom wall 137 of the cavity 134.Each of the cam fingers 136, 138 and 140 has a chamfered edge located onthe top corners 139 that are located away from the side wall 133. Theedges 145 of the cam fingers 136 and 140 that extend downwardly from thecorners 139 are sloped at a positive angle so that they extend away fromwall 133 as they extend downwardly to join bottom wall 137. In contrast,the chamfered corner 139 on the central cam finger 138 terminates at ahard corner 141 that protrudes slightly beyond the edges 145 of camfingers 136 and 140 to form an undercut, and then extends at a negativeangle, such that its forward edge 149 extends slightly in a directiontowards wall 133 as it extends towards bottom wall 137. The hard corner141 provides a primary point of camming contact with the barrel 82 (andin particular, central projection 110 thereof) to lock and unlock (orconnect and disconnect) the barrel 82 to the headgear attachment clip 14as will be described. The cavity 134 includes an elongated channel 135that does not contain the cam fingers 136, 138 and 140. An outer wall148 of the headgear attachment clip 14 defines one end of the cavity134, opposite the wall 133. The top portion of wall 148 includes achamfered top portion 151, and also includes a pair of overhangs 143.The overhangs 143 serve a similar function to the hard corner 141, butengage with semi-cylindrical surfaces 91 and 93 respectively (see FIG.14), as will be described.

As shown in FIG. 22, the front face 116 of the headgear attachment clips14 includes three rectangular openings 142, 144 and 146 that are locatedin the wall 137. The three rectangular openings 142, 144 and 146 extendinto the channel 135 of the cavity 134 on the rear face 118 (see FIG.23). The openings 142 and 146 are disposed closely to outer wall 148,while the opening 144 is offset and disposed at the bottom of slopingsurface 149 of cam finger 138.

The headgear attachment clips 14 along with the headgear straps 40 areconnected to their respective headgear attachment members 22 by movingthe headgear attachment clips 14 toward the barrels 82 so that thechannel 135 of the headgear attachment clips 14 are forced onto thebarrels 82 of the headgear attachment members 22. Specifically, the camfinger 138 (and specifically, the hard corner 141) of the headgearattachment clips 14 engages with the corresponding semi-circularprojection 110 of the barrel 82, and the overhangs 143 of the headgearattachment clips 14 engage with the surfaces 91 and 93 on the oppositeside of the barrel 82. A camming motion between the cam finger 138 ofthe headgear attachment clips 14 and the corresponding circularprojection 110 of the barrel 82 of the headgear attachment members 22causes a bending of the web portions 78, and a slight flexing of the camfinger 138 and/or circular projection 110 to allow the circularprojection 110 to move past the hard corner 141 and into the channel135. Similarly, the flexing movement of web 78, together with slightflexing of the overhangs 143 and/or surfaces 91 and 93 enable thesurfaces to be cammed passed the overhangs 143. When the barrel 82 isdisposed within channel 135, the overhangs 143 and the hard corner 141prevents the barrel 82 from escaping the channel 135. The overhangs 143of the headgear attachment clips 14 engage with the surfaces 91 and 93on the opposite side of the barrel 82, thus allowing for rotation of theheadgear attachment clip 14 during adjustment or to accommodatedifferent head sizes.

In this embodiment, the mask assembly may be provided with an additionalstrap, not shown, connected between the auxiliary openings 152 and belowthe chin. This construction provides additional under-the-chin supportfor the mask 12 to hold it in place rather than permitting it to ride upthe patient's face.

The flexible peripheral seal structure 20 of the mask body 12 may bemade of a relatively soft and/or flexible material so that the flexibleperipheral seal structure 20 conforms to the shape of a patient's facewhen held against it. The flexible peripheral seal structure 20 may bemade of, for example, silicone, an elastomeric material or any othersuitable shape conforming material as will be appreciated by one skilledin the art. Different regions of the flexible peripheral seal structure20 around the perimeter of the mask body 12 may have differentcross-sectional configurations. Various other flexible peripheral sealstructure 20 configurations will become apparent to those skilled in theart. The flexible peripheral seal structure 20 is generally annular toform a seal around the nose and the mouth and may be generally oblongshaped, pear shaped (as shown in FIG. 13) or any other suitable shape aswill be appreciated by one skilled in the art. The rigid portion 21 ofthe mask body 12, in one embodiment, is made of a relatively more rigidmaterial than the flexible peripheral seal structure 20. For example,mask body 12 may be made from polycarbonate, or other suitable material.

The mask body 12 may be formed by a two-step insert molding process. Forexample, the rigid portion 21 may be molded first and then inserted intoa second mold for the flexible peripheral flexible peripheral sealstructure 20, which is injection molded to form around and/or into therigid portion 21.

In one embodiment, the headgear assembly 11 that is used to mount themask body 12 to the head of a patient 27 takes the form of straps.However, any structure that secures the mask body 12 to the head of apatient can be used. In the illustrated embodiment as shown in FIGS. 1Aand 1B, an end potion 41 of each of the two headgear straps 40 (only oneshown in FIG. 1B) is threaded through the elongated opening 50 of theheadgear retaining tab 24, and the end portion 41 of the lower headgearstraps 40 are threaded through the elongated opening 130 of the headgearattachment clip 14. In one embodiment, the end portion 41 comprise hookmaterial and is bent back into engagement with the adjoining surface401, formed of loop material, on the straps 40 so as to form a hook andloop (or VELCRO) type connection. It is to be appreciated, however, thatthere are numerous other ways for securing the end portion of theheadgear strap to itself or to the headgear attachment clip 14 and/or tothe headgear attachment tab 24, such as a snap connection, buckle, orlocking clamp, as non-limiting examples. The headgear 11 is adjustable,as the straps 40 can be pulled further through the opening 50 of theheadgear retaining tab 24 or the elongated opening 130 of the headgearattachment clip 14 to accommodate smaller diameter head sizes.

In addition, in another embodiment, a more permanent attachment of theend portion of the headgear strap 40 to the headgear strap retainingtabs 24 or the headgear attachment clips 14 may be provided. Forexample, once the patient/user 27 sets the headgear strap 40 to thedesired length and threaded in through the elongated opening 50 of theheadgear strap retaining tabs 24 or the elongated opening 130 of theheadgear attachment clips 14, the free end of the strap 40 can bepermanently fixed back onto the strap 40, such as by gluing, sewing, orriveting the overlapping straps together. The straps 40 of the headgearassembly 11 may be elastic or inelastic, and may extend around the backof the head of the patient 27 to secure the mask body 12 on the patient27, with the flexible peripheral seal structure 20 in sealing engagementwith the patient's face.

The mask, as shown in FIG. 1, is a total face mask that accommodatessubstantially the entire facial area (including the nose, the mouth andthe eyes) of the patient. It is to be understood, however, that thepresent invention also contemplates an oral/nasal mask that accommodatesonly the mouth and the nose of a user. The configuration of the mask mayvary and is not limited to a particular size or configuration, aspatients may range in age, size, and/or medical purpose so as to requireappropriate selection from among a variety of different mask sizes andconfigurations as would be appreciated by one skilled in the art. In oneembodiment, the size of the face mask is embossed on the lower endportion of the flexible peripheral seal structure 20 as shown by 600 inFIG. 13.

Although the invention has been described in detail for the purpose ofillustration based on what is currently considered to be the mostpractical and preferred embodiments, it is to be understood that suchdetail is solely for that purpose and that the invention is not limitedto the disclosed embodiments, but, on the contrary, is intended to covermodifications and equivalent arrangements that are within the spirit andscope of the appended claims. For example, it is to be understood thatthe present invention contemplates that, to the extent possible, one ormore features of any embodiment can be combined with one or morefeatures of any other embodiment.

What is claimed is:
 1. A mask assembly for providing gas to a patient,comprising: a mask body having an opening for reception of the gas, themask body including a seal structure for sealingly engaging with theface of the patient and surrounding at least the nose and mouth of thepatient, the mask body having a connecting portion; and a conduitreleasably connected with the connecting portion of the mask body fordelivering the gas to the patient through the opening, the conduitcomprising a first connector portion which connects with the connectingportion, and a second connector portion constructed and arranged toconnect with tubing, wherein the first connector portion comprises aplurality of recesses at an interface with the connecting portion toallow exhaled gas to escape therethrough.